Mask and a production method therefor

ABSTRACT

A mask and a method of manufacturing the same that intercept a virus are provided. The mask includes: a mask body; an exhalation module that is formed at one surface of the mask body; and an inhalation module that is formed at the one surface of the mask body and that includes an inhalation filter. The inhalation filter includes an anodized aluminum oxide film.

FIELD OF THE INVENTION

The present invention relates to a mask and a method of manufacturingthe same. More particularly, the present invention relates to a mask anda method of manufacturing the same that intercept a virus.

DESCRIPTION OF THE RELATED ART

A mask is a stuff for covering respiratory organs such as a nose and amouth in order to intercept a scattering material such as a dust and avirus, and a general mask is formed in a simple structure having afilter of a simple structure in order to conveniently carry, unlike anantigas mask.

Generation of an environment contamination material continuouslyincreases according to industrialization, and as a threat of variousviruses rises, a hygiene equipment of a higher level is requested.Particularly, nowadays, as a new type virus such as a corona virus ofsevere acute respiratory syndrome (SARS), swine influenza (SI), andavian influenza (AI) occurs, a demand of a mask for preventing infectionthereof increases.

Most viruses have a size of about 10 nm to about 300 nm, andparticularly, a corona virus of SARS has a size of about 100 nm, and SIhas a size of about 80 nm to about 120 nm.

However, a size of a particle that can be intercepted by an N95 maskthat is encouraged by World Health Organization (WHO) is merely about300 nm. Further, an existing widely used dust-proof mask filters by anadsorption method using permanent electrostatic fiber and activatedcarbon, and by such a method, a material of about 300 nm or more can beintercepted and thus perfect interception of a virus including a newtype virus is impossible.

The above information disclosed in this Background section is only forenhancement of understanding of the background of the invention andtherefore it may contain information that does not form the prior artthat is already known in this country to a person of ordinary skill inthe art.

DESCRIPTION OF THE INVENTION Technical Object

The present invention has been made in an effort to provide a maskhaving advantages of intercepting a virus of a micro size.

The present invention further provides a mask that can intercept a virusby a simple method.

Technical Solution

An exemplary embodiment of the present invention provides a maskincluding: a mask body; an exhalation module that is formed at onesurface of the mask body; and an inhalation module that is formed at theone surface of the mask body and that includes an inhalation filter. Theinhalation filter includes an anodized aluminum oxide film.

A plurality of holes may be formed in the aluminum oxide film, and theplurality of holes each may have a diameter of 18 nm to 40 nm.

The aluminum oxide film may be formed in a honeycomb structure.

The inhalation filter may further include a fiber that is disposed atboth surfaces of the aluminum oxide film; and a net-shaped partitionthat is disposed between the aluminum oxide film and the fiber.

The inhalation module may include an inhalation housing that houses theinhalation filter. The exhalation module may include an opening andclosing film; a net-shaped partition that is disposed at one surface ofthe opening and closing film; and an exhalation housing that houses theopening and closing film and the partition.

The mask may further include an adhesive module that is formed along anedge of the mask body at the other one surface of the mask body in whichthe inhalation module and the exhalation module are not formed.

The adhesive module may be a double-sided adhesive tape.

The exhalation module may be formed in a central portion of the maskbody, and the inhalation module may be formed in a pair in symmetryabout the exhalation module.

Another embodiment of the present invention provides a method ofmanufacturing a mask, the method including: preparing a mask body;forming an inhalation module inserting port and an exhalation moduleinserting port in the mask body; and mounting an inhalation moduleincluding an inhalation filter and an exhalation module in theinhalation module inserting port and the exhalation module insertingport, respectively. The inhalation filter may be formed by forming analuminum oxide film by forming a hole by anodizing aluminum and bydisposing a net-shaped partition and fiber at both surfaces of thealuminum oxide film.

The method may further include forming the aluminum oxide film andperforming an etching process in order to adjust a size of a hole thatis formed in the aluminum oxide film.

The method may further include anodizing the aluminum and removing anunoxidized aluminum layer.

The method may further include forming a double-sided adhesive tapealong an edge of the other one surface of the mask body in which theinhalation module and the exhalation module are not formed.

The exhalation module may be formed in a central portion of the maskbody, and the inhalation module may be formed in a pair in symmetryabout the exhalation module.

According to an exemplary embodiment of the present invention, a virusof several ten nm sizes can be effectively intercepted.

Further, by manufacturing a mask having a high virus interception effectby a simple method, a production cost is reduced, and productivity canbe improved.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating a mask according to anexemplary embodiment of the present invention.

FIG. 2 is a schematic diagram illustrating a mask body according to anexemplary embodiment of the present invention.

FIG. 3 is a schematic diagram illustrating an inhalation module of amask according to an exemplary embodiment of the present invention.

FIGS. 4A and 4B are schematic diagrams illustrating operation of anexhalation module of a mask according to an exemplary embodiment of thepresent invention.

FIG. 5 is a diagram sequentially illustrating a method of manufacturingan inhalation filter of a mask according to an exemplary embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The present invention will be described more fully hereinafter withreference to the accompanying drawings, in which exemplary embodimentsof the invention are shown.

FIG. 1 is a perspective view illustrating a mask according to anexemplary embodiment of the present invention, and FIG. 2 is a schematicdiagram illustrating a mask body according to an exemplary embodiment ofthe present invention.

Referring to FIG. 1, a mask 100 according to the present exemplaryembodiment includes a mask body 10, an inhalation module 20, and anexhalation module 30.

The inhalation module 20 performs a function of an inflow passage inwhich outside air is injected when inhaling upon using the mask 100, andthe exhalation module 30 performs a function of a discharge passage inwhich air is discharged to the outside when exhaling. Further, the maskbody 10 performs a function of supporting the inhalation module 20 andthe exhalation module 30, and the mask body 10 is formed to have apredetermined curvature to close contact with a face when using the mask100, thereby enabling outside air not to be injected to a periphery ofthe mask 100.

According to the present exemplary embodiment, the exhalation module 30is formed in a central portion of the mask 100, and the inhalationmodule 20 is formed in symmetry at both sides of the mask 100 based onthe exhalation module 30. By such a configuration, when a user wears themask 100, the exhalation module 30 is disposed adjacent to respiratoryorgans, i.e., a nose and a mouth, when the user exhales, discharge airdoes not stay for a long time period within the mask 100 and is rapidlydischarged to the outside of the mask 100.

Referring to FIG. 2, in the mask body 10 according to the presentexemplary embodiment, an inhalation module inserting port 12 and anexhalation module inserting port 13 for inserting the inhalation module20 and the exhalation module 30, respectively, are formed. Diameters ofthe inhalation module inserting port 12 and the exhalation moduleinserting port 13 are formed identical to exterior diameters of theinhalation module 20 and the exhalation module 30, and thus theinhalation module inserting port 12 and the exhalation module insertingport 13 are inserted by forced insertion. Alternatively, after diametersof the inhalation module inserting port 12 and the exhalation moduleinserting port 13 are formed larger than exterior diameters of theinhalation module 20 and the exhalation module 30, respectively, whenthe inhalation module 20 and the exhalation module 30 are inserted, theremaining space may be filled with an adhesive member and thus theinhalation module 20 and the exhalation module 30 may be fixed to themask body 10.

By such a structure, after the inhalation module 20 and the exhalationmodule 30 are inserted into the inhalation module inserting port 12 andthe exhalation module inserting port 13, respectively, the inhalationmodule 20 and the exhalation module 30 are stably fixed. After theinhalation module 20 and the exhalation module 30 are inserted into theinhalation module inserting port 12 and the exhalation module insertingport 13 and are fixed to the inhalation module inserting port 12 and theexhalation module inserting port 13, respectively, a sealing member maybe additionally formed to fill a micro gap that may occur by a toleranceof the inhalation module 20, the exhalation module 30, or each of theinserting ports 12 and 13 thereof.

In the mask body 10, in order not to inject or discharge air as well asa virus of a micro size, a pore is not formed. For this purpose, themask body 10 is made of a material such as plastic and rubber. That is,when the user wear the mask 100 and breathes, inhalation and exhalationare injected and discharged through the inhalation module 20 and theexhalation module 30, respectively, and air is not injected and ejectedthrough the mask body 10 and thus a virus can be effectivelyintercepted.

The mask body 10 includes an adhesive module 11 that is formed along anedge of the mask body 10. The adhesive module 11 is formed with adouble-sided adhesive tape that may be easily attached to and removedfrom a skin, and the mask 100 close contacts with a face through theadhesive module 11. Because outside air is not injected into or ejectedfrom the periphery of the mask 100 due to a configuration of theadhesive module 11, air is injected and discharged through theinhalation module 20 and the exhalation module 30. A string that may behooked to ears instead of the adhesive module 11 of the presentexemplary embodiment is connected to both sides of the mask body 10 toenable the mask 100 to close contact with a face. Alternatively, theadhesive module 11 may be formed in the mask body 10, and at both sidesof the mask body 10, a string may be simultaneously additionally formed.

FIG. 3 is a schematic diagram illustrating an inhalation module of amask according to an exemplary embodiment of the present invention, anda configuration of the inhalation module 20 according to the presentexemplary embodiment will be described with reference to FIG. 3.

The inhalation module 20 according to the present exemplary embodimentincludes an inhalation filter 21 and an inhalation housing 23. Theinhalation filter 21 is formed to intercept a virus of a micro size of anano scale, and the inhalation housing 23 is inserted into theinhalation module inserting port 12 of the mask body 10 to be fixed tothe inhalation module inserting port 12 while housing the inhalationfilter 21.

The inhalation module 20 according to the present exemplary embodimentperforms a function of filtering injected air when generally inhaling,but performs a function of a discharge passage of exhalation whenexhaling together with the exhalation module 30, thereby enablingbreathing to be smoothly performed.

A configuration of the inhalation filter 21 will be specificallydescribed with reference to a right portion of FIG. 3. The inhalationfilter 21 according to the present exemplary embodiment includes analuminum oxide film 21 a, dust-free fibers 21 c that are disposed atboth surfaces of the aluminum oxide film 21 a, and partitions 21 b thatare disposed between the aluminum oxide film 21 a and the dust-freefiber 21 c.

The aluminum oxide film 21 a is formed by anodizing aluminum, and aplurality of holes of a nano scale are formed in the aluminum oxide film21 a according to the present exemplary embodiment. In order to preventa virus such as a corona virus of SARS and SI from passing through, eachhole that is formed in the aluminum oxide film 21 a has a diameter ofabout 18 nm to about 40 nm. In this case, the aluminum oxide film 21 ais formed in a honeycomb form that is formed in a plurality of hexagonalpillars having the hollow center. A specific method of manufacturingsuch an aluminum oxide film 21 a will be described later.

At both surfaces of the aluminum oxide film 21 a, the dust-free fibers21 c are disposed. The dust-free fiber 21 c is made of fabric, knitwear,and non-woven fabric, and may be formed using the fabric, the knitwear,and the non-woven fabric as a single material or may be formed in astructure in which a non-woven fabric layer is disposed between thefabric or the knitwear. In this way, the dust-free fiber 21 c that ismade of fabric, knitwear, and non-woven fabric is disposed at an inletand an outlet of the aluminum oxide film 21 a to perform a function offiltering a dust that may be included in inflow air and discharge air.

The partitions 21 b are each disposed between the aluminum oxide film 21a and the dust-free fibers 21 c that are disposed at both surfaces ofthe aluminum oxide film 21 a. The partition 21 b prevents damage fromoccurring when the aluminum oxide film 21 a contacts with the dust-freefiber 21 c and is made of plastic in consideration of protection andstrength security of the aluminum oxide film 21 a. Further, in order toprevent inflow air or discharge air, having passed through the dust-freefiber 21 c and the aluminum oxide film 21 a from be intercepted, thepartition 21 b is formed in a net-shaped partition having a void of anenough size.

As described above, the inhalation filter 21 including the aluminumoxide film 21 a, the dust-free fiber 21 c, and the partition 21 b ishoused in and is fixed to the inhalation housing 23. The inhalationhousing 23 is made of plastic to have enough strength to protect theinhalation filter 21.

When the user wears the mask 100 and breaths according to the presentexemplary embodiment, inhalation is injected through the inhalationmodule 20 of the above-described configuration, and thus a virus of amicro size, specifically, about 50 nm as well as a dust can beeffectively intercepted.

FIGS. 4A and 4B are schematic diagrams illustrating operation of anexhalation module of a mask according to an exemplary embodiment of thepresent invention, and a configuration of the exhalation module 30according to an exemplary embodiment of the present invention will bedescribed with reference to FIGS. 4A and 4B.

The exhalation module 30 according to the present exemplary embodimentincludes an opening and closing film 31, a partition 32, and anexhalation housing 33 that houses the opening and closing film 31 andthe partition 32.

In the opening and closing film 31, a pore is not formed and thus in abreathing process, the opening and closing film 31 is formed not topenetrate air. For this purpose, the opening and closing film 31 is madeof a material such as rubber. The partition 32 supports the opening andclosing film 31 and is formed to enable air to penetrate the opening andclosing film 31 in a breathing process, particularly, an exhalingprocess. For this purpose, the partition 32 is formed in a net shapeusing a material such as plastic. The exhalation housing 33 houses theopening and closing film 31 and the partition 32, and in order toprotect the opening and closing film 31 and the partition 32, theexhalation housing 33 is made of plastic to have enough strength, andthe exhalation housing 33 is inserted into and is fixed to theexhalation module inserting port 13 of the mask body 10.

One end of the opening and closing film 31 is fixed to the housing 33,and the other end of the opening and closing film 31 that is not fixedto the housing 33 is formed to move in a vertical direction (see FIG.4A). Further, the partition 32 is fixed within the housing 33 along acircumference thereof to support the opening and closing film 31.

FIG. 4A is a diagram illustrating operation of an exhalation module inan inhaling process, and referring to FIG. 4A, as an inhaling force isapplied in a mask direction (a direction A), the opening and closingfilm 31 moves in a mask direction (a direction A). Because the partition32 is fixed within the housing 33, the opening and closing film 31 closecontacts with the partition 32, and by the opening and closing film 31in which a pore is not formed, air is not injected in the mask direction(the direction A) through the exhalation module 30.

Accordingly, when the user wears the mask 100 and inhales, air is notinjected by the exhalation module 30 but is injected only by theinhalation module 20 and thus a virus of a micro size as well as a dustcan be effectively intercepted.

FIG. 4B is a diagram illustrating operation of an exhalation module inan exhaling process, and referring to FIG. 4B, as a pressure is appliedin a direction opposite to the mask direction (the direction A), theother end of the opening and closing film 31 that is not fixed to thehousing 33 moves in a direction opposite to the mask direction (thedirection A). That is, the other end of the opening and closing film 31that is not fixed to the housing 33 is separated from the partition 32and moves to an upper part (see FIG. 4B) within the housing 33.

Accordingly, when the user wears the mask 100 and exhales, exhalation isdischarged to a gap that is formed when the net-shaped partition 32 andthe opening and closing film 31 move to an upper part within the housing33.

Air may be discharged through a configuration of such an exhalationmodule 30, and particularly, as the exhalation module 30 is formed in acentral portion of the mask 100, the exhalation module 30 enables theair to be smoothly discharged to the outside of the mask 100. Further,because air may be discharged through the inhalation module 20, air israpidly discharged.

As described above, the mask 100 according to an exemplary embodiment ofthe present invention can effectively intercept a virus of a micro sizeof about 50 nm and thus secures safe activity of the user without alimitation to an outside environment.

FIG. 5 is a diagram sequentially illustrating a method of manufacturingan inhalation filter of a mask according to an exemplary embodiment ofthe present invention, and hereinafter, a method of manufacturing a maskaccording to an exemplary embodiment of the present invention will bedescribed with reference to FIGS. 1 to 5.

The method of manufacturing the mask 100 according to the presentexemplary embodiment includes steps of preparing the mask body 10,forming the inhalation module inserting port 12 and the exhalationmodule inserting port 13 in the mask body 10, and mounting theinhalation module 20 and the exhalation module 30 in the inhalationmodule inserting port 12 and the exhalation module inserting port 13,respectively.

The mask body 10 is made of a material such as plastic and rubber inwhich a pore is not formed, and the inhalation module 20 and theexhalation module 30 are mounted in the inhalation module inserting port12 and the exhalation module inserting port 13, respectively, by aforced insertion method, or are mounted using an adhesive member. Inthis case, in order to fill a micro gap that may occur by a tolerancebetween the inhalation module 20 and the exhalation module 30 andbetween the inhalation module inserting port 12 and the exhalationmodule inserting port 13, a sealant may be additionally applied.

The inhalation module 20 is formed to house the inhalation filter 21within the inhalation housing 23 that is made of a plastic material. Theinhalation filter 21 is formed by sequentially stacking the partition 21b and the dust-free fiber 21 c at both surfaces of the aluminum oxidefilm 21 a, and by fixing them within the inhalation housing 23, theinhalation module 20 is formed.

Referring to FIG. 5, a method of forming an aluminum oxide filmaccording to the present exemplary embodiment will be described indetail. In order to form the aluminum oxide film 21 a, an aluminumsubstrate 50 is prepared, and by anodizing the aluminum substrate 50, analuminum oxide layer 51 and an unoxidized aluminum layer 52 are formed.

Anodization is technology that makes metal oxide by electrochemicallyoxidizing a metal, and when generally anodizing aluminum, aligned porousaluminum oxide is obtained. In the present exemplary embodiment, thealuminum oxide layer 51 that is formed through anodization has a porousstructure in which a plurality of holes are regularly formed, and thealuminum oxide layer 51 is formed in a honeycomb structure, which is anaggregate of a hexagonal pillar having the hollow center.

In this way, after the aluminum oxide layer 51 is formed throughanodization, in order to adjust a size of a hole that is formed in thealuminum oxide layer 51, an etching process is performed. When a portionof the aluminum oxide layer 51 is etched, an aluminum oxide pillar 51 aand an aluminum oxide lower layer 51 b are formed, and thus a hole of anappropriate size is formed according to use of the mask 100.

Thereafter, by selectively etching the aluminum layer 52 that is formedin a lower portion of the aluminum oxide lower layer 51 b, the aluminumlayer 52 is removed, and by removing the aluminum oxide lower layer 51 bthrough etching, the aluminum oxide film 21 a having opened both sidesis formed.

The aluminum oxide film 21 a that is used for the inhalation filter 21is formed by a simple method through such a process. Further, because asize of a hole that is formed in the aluminum oxide film 21 a may beadjusted in a process, the mask 100 that can intercept dusts or virus ofvarious sizes according to a use purpose and a use environment isproduced.

The exhalation module 30 is formed by housing the opening and closingfilm 31 and the partition 32 in the exhalation housing 33 that is madeof a plastic material. In this case, the partition 32 is formed in a netshape of a plastic material and is fixed to the housing 33 not to movewithin the housing 33. Further, the opening and closing film 31 is madeof rubber in which a pore is not formed, one end thereof is fixed to thehousing 33, and in a breathing process, the other end that is not fixedto the housing 33 may be moved.

In this way, by a method of manufacturing the mask 100 according to thepresent exemplary embodiment, the mask 100 that can effectivelyintercept a virus of a micro size as well as a dust can be produced by asimple method and thus a production cost can be reduced, andproductivity can be improved.

While this invention has been described in connection with what ispresently considered to be practical exemplary embodiments, it is to beunderstood that the invention is not limited to the disclosedembodiments, but, on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims.

1. A mask, comprising: a mask body; an exhalation module that is formedat one surface of the mask body; and an inhalation module that is formedat the one surface of the mask body and that comprises an inhalationfilter, wherein the inhalation filter comprises an anodized aluminumoxide film.
 2. The mask of claim 1, wherein a plurality of holes areformed in the aluminum oxide film, and the plurality of holes each havea diameter of 18 nm to 40 nm.
 3. The mask of claim 1, wherein thealuminum oxide film is formed in a honeycomb structure.
 4. The mask ofclaim 1, wherein the inhalation filter further comprises a dust-prooffiber that is disposed at both surfaces of the aluminum oxide film; anda net-shaped partition that is disposed between the aluminum oxide filmand the fiber.
 5. The mask of claim 1, wherein the inhalation modulecomprises an inhalation housing that houses the inhalation filter. 6.The mask of claim 1, wherein the exhalation module comprises an openingand closing film; a net-shaped partition that is disposed at one surfaceof the opening and closing film; and an exhalation housing that housesthe opening and closing film and the partition.
 7. The mask of claim 1,further comprising an adhesive module that is formed along an edge ofthe mask body at the other one surface of the mask body in which theinhalation module and the exhalation module are not formed.
 8. The maskof claim 7, wherein the adhesive module is a double-sided adhesive tape.9. The mask of claim 1, wherein the exhalation module is formed in acentral portion of the mask body, and the inhalation module is formed ina pair in symmetry about the exhalation module.
 10. A method ofmanufacturing a mask, the method comprising: preparing a mask body;forming an inhalation module inserting port and an exhalation moduleinserting port in the mask body; and mounting an inhalation module andan exhalation module comprising an inhalation filter in the inhalationmodule inserting port and the exhalation module inserting port,respectively, wherein the inhalation filter is formed by forming analuminum oxide film by forming a hole by anodizing aluminum and bydisposing a net-shaped partition and fiber at both surfaces of thealuminum oxide film.
 11. The method of claim 10, further comprisingforming the aluminum oxide film and performing an etching process inorder to adjust a size of a hole that is formed in the aluminum oxidefilm.
 12. The method of claim 10, further comprising anodizing thealuminum and removing an unoxidized aluminum layer.
 13. The method ofclaim 10, further comprising forming a double-sided adhesive tape alongan edge of the other one surface of the mask body in which theinhalation module and the exhalation module are not formed.
 14. Themethod of claim 10, wherein the exhalation module is formed in a centralportion of the mask body, and the inhalation module is formed in a pairin symmetry about the exhalation module.